Research Projects

The High Voltage Optical Film (HVOF) system is a popular method for producing coatings for components exposed to extreme wear and corrosion. It offers benefits such as higher bond strength, lower porosity, and faster deposition rate, making it a popular choice for engineering applications. The HVOF technique is efficient and cost-effective, but its performance and microstructure are influenced by gas dynamics and particle in-flight flow variables. The properties of coatings are also influenced by the geometry of the nozzle, spray distance, and process parameters. The HVOF system is complex, involving supersonic/subsonic flow transition, heat transfer, and multi-phase turbulent flow. The effect of processing conditions on coating properties and particle characteristics is nonlinear and difficult to examine by experimental measurements. Therefore, computational modeling has become an essential tool in the design and operation of HVOF systems. The proposed project aims to provide guidelines for understanding gas dynamics and particle behavior, optimize process parameters, and design future HVOF devices in India. The project will include an accurate RANs-based turbulence model for liquid-fueled HVOF systems, detailed investigation of PANs and LEs turbulence models for gas-fueled HVOF systems, experimental investigation of in-flight particle state and microstructure formation, and assessment of coating quality parameters like percentage porosity, surface roughness, microhardness, and bond strength.